SICK Flexi Classic series Operating Instructions Manual Download

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Flexi Classic

O P E R A T I N G I N S T R U C T I O N S

Modular Safety Controller

Summary of Contents for Flexi Classic series

Page 1: ...Flexi Classic O P E R A T I N G I N S T R U C T I O N S en Modular Safety Controller ...

Page 2: ...ent is protected by the law of copyright whereby all rights established therein remain with the company SICK AG Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law Alteration or abridgement of the document is not permitted without the explicit written approval of the company SICK AG ...

Page 3: ...nsion module 18 3 2 4 UE410 XU input output extension 18 3 2 5 UE410 2RO UE410 4RO output modules 18 3 2 6 Gateways 18 3 2 7 Module overview adjustments and facilities for connecting sensors 19 3 3 UE410 MU main module 22 3 3 1 Controls and status indicators 24 3 3 2 Terminal assignment 25 3 3 3 Outputs 26 3 4 UE410 GU main module 27 3 4 1 Controls and status indicators 28 3 4 2 Terminal assignmen...

Page 4: ...al applications and functions 60 4 1 RE300 magnetic safety switch 61 4 2 IN4000 inductive safety switch 62 4 3 Testable single beam photoelectric safety switches 63 4 4 Two hand operation jog mode 66 4 5 OR function 67 4 6 Muting function 68 4 6 1 Muting with two sensors 69 4 6 2 Muting cycle 69 4 6 3 Muting sensors 69 4 7 Placement of muting sensors 70 4 7 1 Muting with two sensors a sensor pair ...

Page 5: ...nfiguration 92 10 Diagnostics 93 10 1 In the event of faults or errors 93 10 2 Replacement of a module 93 10 3 SICK support 94 10 4 Error indications of the ERR error LED 94 10 5 Anti manipulation measures 95 11 Technical specifications 96 11 1 Data sheet 96 11 1 1 UE410 MU UE410 XU modules 96 11 1 2 UE410 GU module 101 11 1 3 UE410 8DI input extension module 105 11 1 4 UE410 2RO UE410 4RO output ...

Page 6: ...ms which are to be protected by a Flexi Classic modular safe ty controller They are also addressed to people who integrate the Flexi Classic modular safety controller into a machine initialise its use or who are in charge of servicing and maintaining the device 1 3 Information depth These operating instructions contain the following information on the Flexi Classic modular safety controller mounti...

Page 7: ...e modules 1 5 Abbreviations External device monitoring Electro sensitive protective equipment e g C4000 Output signal switching device Programmable logic controller Safety Integrity Level SIL claim limit 1 6 Symbols used Refer to notes for special features of the device LED symbols describe the state of a diagnostics LED Examples Ν The LED is illuminated constantly The LED is flashing ν The LED is...

Page 8: ...tton Electro sensitive protective equipment ESPE Sensors that can be tested e g photoelectric switches Inductive safety sensors e g IN4000 Two hand operating panel IIIA Two hand operating panel IIIC Jog mode via two hand operating panel IIIA time limit 5 s Muting lamp and Reset required lamp not monitored Lamp permanently ON Muting active Lamp flashing 1 Hz Reset required Pressure sensitive mats 4...

Page 9: ...ject to change without notice About this document Symbol Module functions Bypass function with electro mechanical dual channel equivalent switch e g enabling switch Bypass function limited to 60 s Muting station with two inputs for muting sensors Retriggering Monitored semiconductor output Off delay ENABLE EN Tab 2 Module function symbols ...

Page 10: ...onitoring of synchronisation 1500 ms Dual channel N C contact equivalent cross circuit detecting Dual channel N C contact equivalent Dual channel N C N O contact complementary cross circuit detecting Dual channel N C N O contact complementary cross circuit detecting with monitoring of synchronisation 1500 ms e g magnetically coded switch RE300 Dual channel semiconductor input monitored ESPE Single...

Page 11: ...for safety applications The category in accordance with EN ISO 13849 1 or the SIL in accordance with IEC 61508 and the SILCL in accordance with EN 62061 depend on the external circuit the realisation of the wiring the choice of the sensors and their location at the machine The device corresponds to up to category 4 in accordance with EN ISO 13849 1 appli cations can reach up to SIL3 in accordance ...

Page 12: ...Voltage Directive 2006 95 EC valid until 19 04 2016 Low Voltage Directive 2014 35 EU valid from 20 04 2016 The work safety regulations safety rules Manufacturers and owners of the machine on which a Flexi Classic is used are responsible for obtaining and observing all applicable safety regulations and rules The notes in particular the test notes see chapter 8 Commissioning on page 90 of these oper...

Page 13: ...st be carried out with the greatest accuracy and must match the status and the condition of the machine or system to be monitored Check whether the configured safety application monitors the machine or system as planned and whether the safety of a configured application is ensured at all times This must be ensured in each operating mode and partial application Document the result of this check In ...

Page 14: ...aste Code 16 02 14 We would be pleased to be of assistance to you on the disposal of these devices Contact us 2 5 2 Separation of materials Material separation may only be performed by qualified safety personnel Caution is required when dismantling devices There is a risk of injuries Before you send the devices for appropriate recycling it is necessary to separate the different materials in the Fl...

Page 15: ...c series is a safety controller concept comprising different modules that can be interconnected individually This allows the system to be extended to up to 104 inputs or outputs Each of these modules has a compact width of 22 5 mm The units are of plug in style with communication between the individual units over an internal bus The required logic and function is specified by means of rotary switc...

Page 16: ...odule 3 2 1 UE410 MU main module The UE410 MU is the main module in which the system configuration of the entire Flexi Classic system is stored The UE410 MU has 4 safety inputs 4 semiconductor outputs and 2 test outputs The 9 programs that are available can be set by means of rotary switches that ensure the connection of a large number of safety components Functions such as EDM resetting etc are s...

Page 17: ...em is saved in the UE410 GU The UE410 GU makes possible a global emergency stop function for sev eral stations connected together that must each be equipped with a UE410 GU A local emergency stop is also possible on each UE410 GU The UE410 GU has 4 safety inputs I1 I4 1 semiconductor output Q1 1 output for a lamp for Global emergency stop status and Reset required Q2 2 test outputs X1 X2 and 2 inp...

Page 18: ...UE410 MU and UE410 GU the UE410 XU cannot store the system configuration A UE410 XU can only be operated in combination with a UE410 MU or UE410 GU main module A main module and a UE410 XU can be linked logically with each other thus forming a subsystem for further information please refer to section 4 12 Grouping of subsys tems on page 78 3 2 5 UE410 2RO UE410 4RO output modules The UE410 2RO UE4...

Page 19: ...inputs Information coupling to the upstream UE410 MU UE410 GU or UE410 XU module UE410 2RO 2 contacts N O 1 signal contact N C UE410 4RO 4 contacts N O 2 signal contacts N C Flexi Classic gateways e g UE410 PRO UE410 DEV UE410 CAN Status and diagnostics information that is not safety relevant of a Flexi Classic on a fieldbus see Flexi Classic Gateways operating instructions Setting possibility Can...

Page 20: ...o change without notice Product description Program UE410 MU UE410 XU UE410 8DI Sensor A I1 I2 B I3 I4 A I1 I4 B I5 I8 7 8 1 2 7 8 9 1 6 7 1 6 7 7 8 1 2 7 8 9 6 7 6 7 1 5 6 9 5 6 2 3 8 2 3 8 4 4 2 5 5 1 2 2 3 7 8 1 2 7 8 9 6 7 6 7 3 7 8 1 2 7 8 9 6 7 6 7 3 7 8 1 2 7 8 9 6 7 6 7 Tab 8 Connection of sen sors to the UE410 MU UE410 XU and UE410 8DI ...

Page 21: ...Industrial Safety Systems Germany All rights reserved 21 Subject to change without notice Product description Program UE410 MU UE410 XU UE410 8DI Sensor A I1 I2 B I3 I4 A I1 I4 B I5 I8 4 4 5 2 5 1 2 5 5 3 1 5 6 7 8 1 2 6 7 8 9 2 3 6 7 8 2 3 6 7 8 3 1 1 3 3 1 5 6 9 5 6 2 3 8 2 3 8 ...

Page 22: ... that are depen dent on each other In order to increase the number of inputs one or more UE410 8DI extension modules can be used additionally An additional UE410 XU module can be used in order to increase the number of outputs for further information refer to section 4 12 Grouping of subsystems on page 78 The system configuration is stored in the UE410 MU main module ENTER button to accept the pro...

Page 23: ...onse time Q3 1 and Q4 can be deactivated with off delay by using the lower rotary switch depending on the device variant 0 5 s 0 50 s 0 300 s not on UE410 xxxT0 The outputs are tested periodically in order to detect errors in the safety outputs Q1 Q4 When using XU modules see section 4 12 Grouping of subsystems on page 78 For further information see section 3 6 UE410 MU UE410 XU programs on page 3...

Page 24: ...nal status on the whole system the error is on another module see chapter 10 Diagnostics on page 93 EN S1 S3 green Voltage is present I1 I4 green Signal is present I1 I2 flash in phase Cross circuit between I1 I2 I3 I4 flash in phase Cross circuit between I3 I4 I1 I2 flash out of phase Process error at I1 I2 I3 I4 flash out of phase Process error at I3 I4 I1 to I4 flashes Synchronization time conc...

Page 25: ...3 3 2 Terminal assignment Assignment Description I1 I2 Input for logic path A I3 I4 Input for logic path B EN ENABLE input activates the logic path s S1 S2 S3 Input for reset buttons RESET restart interlock EDM retriggering etc A1 UB A2 GND Voltage supply X1 X2 Test outputs cross circuit detecting and short circuit detecting control signals for controlling safety sensors 3 Q1 Q4 Monitored semicond...

Page 26: ...ions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the safety outputs Wire the Flexi Classic system so that 24 V DC signals cannot contact the safety outputs Connect the GND wires of the power supply to earth so that the devices do not switch on when the safety output line is applied to frame potential Use suitable components or devices that ful...

Page 27: ...cy stop on a module is operated the safety outputs on all modules switch off To reset a glo bal emergency stop the reset button must be operated on the same module on which the global emergency stop was triggered A global emergency stop must always be reset manually Along with the global emergency stop function on each module it is also possible to select a local emergency stop function with or wi...

Page 28: ...hing in phase Cross circuit between I1 I2 I3 I4 green flashing in phase Cross circuit between I3 I4 I1 I2 green flashing out of phase Process error at I1 I2 I3 I4 green flashing out of phase Process error at I3 I4 I5 green External device monitoring contact is closed I6 green Reset button is closed IP green Input IP is high IN green Input IN is high Other indicators Device error see chapter 10 Dia...

Page 29: ...is recommended not to exceed 32 modules because each module increases the response time of the overall system see the infor mation on the global response time in section 11 1 2 UE410 GU module of the tech nical data on page 101 The different UE410 GU modules that together form a global emergency stop circuit do not need to be in the same protected area Faults in the area OX and IX e g a short circ...

Page 30: ...o be noted for the reset Only the falling edge is evaluated The minimum actuation time for the reset button is 50 ms The maximum actuation time for the reset button is 5 s If one of these criteria is not met the emergency stop is not reset Wiring of the modules To connect several UE410 GU modules together the input IN on the previous UE410 GU must be connected to the output OP on the next UE410 GU...

Page 31: ...the program set this module sets its safety output Q1 to low The signals OP and ON remain high i e the local emergency stop only acts on the safety output on the UE410 GU on which the local emergency stop was triggered Once the cause of the local emergency stop has been rectified inputs I3 and I4 are high again e g protective field clear the safety output Q1 on the module switches to high again af...

Page 32: ...ith manual reset is set for the local emergency stop program 2 4 6 or 8 see section 3 7 UE410 GU programs on page 49 If a program with automatic reset is set for the local emergency stop then the reset button only acts on a global emergency stop i e if a global emergency stop has been triggered on the module and the module has the status Reset required 3 4 6 Outputs Lay the single channel connecti...

Page 33: ...ended response time of the overall system on the usage of several UE410 GU modules In a system consisting of several UE410 GU modules connected together the power up delay and the response time are increased depending on the number of UE410 GU mo dules connected together Take this aspect into account on planning your system Other wise the operator of the system will be in danger The response time ...

Page 34: ...on with safety output Q1 active the LEDs I5 and I6 are ν Off LED Meaning I5 illuminates Ν Green The safety output Q1 is shut down the external actuators have dropped out Otherwise check the wiring I5 flashes Green EDM error Check the wiring If necessary replace the actuator I6 illuminates Ν Green The reset button is pressed Otherwise check the wiring I6 flashes Green The reset button has been oper...

Page 35: ...safe inputs and outputs It has the identical functionality to the UE410 MU main module however without the system save using the ENTER button The UE410 XU cannot be used as a stand alone device and always requires a UE410 MU main module 3 5 1 Controls and status indicators Indicators controls and terminal assignments are the same as on the UE410 MU main module see Tab 9 Tab 11 Fig 11 UE410 XU cont...

Page 36: ...instructions Program Description 0 Module inactive 1 2 Input control circuit A is linked by means of OR logic to input control circuit B and acts on all the safety outputs Q1 Q4 3 1 3 2 Input control circuit A acts on the safety outputs Q1 Q2 Q4 Input control circuit B is muting input and controls the muting lamp via Q3 4 Input control circuit AB acts on all the safety outputs AB two hand IIIC 5 7...

Page 37: ...tput OR with UE410 8DI switch position 7 AND with UE410 8DI switch position 1 6 Connecting of S1 with restart interlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 S2 may not be connected OR limited 60 s with UE410 8DI switch position 8 Always wire ENABLE expected 24 V DC At ENABLE low...

Page 38: ...10 8DI switch position 7 AND with UE410 8DI switch position 1 6 Connecting of S1 with restart interlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 S2 may not be connected OR limited 60 s with UE410 8DI switch position 8 Always wire ENABLE expected 24 V DC At ENABLE low Q1 Q4 are alway...

Page 39: ...I switch position 1 6 Connecting of S1 with restart interlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 S2 is connected to UB Connecting of S2 S2 may not be connected OR limited 60 s with UE410 8DI switch position 8 Always wire ENABLE expected 24 V DC At ENABLE low Q1 Q4 are always l...

Page 40: ... 7 AND with UE410 8DI switch position 1 6 Connecting of S1 without restart interlock with two hand control start up testing to EN 574 IIIC with EDM Q1 Q2 without EDM Q1 Q2 Connecting of S2 S2 may not be connected OR limited 60 s with UE410 8DI switch position 8 Always wire ENABLE expected 24 V DC At ENABLE low Q1 Q4 are always low No off delay switch DELAY to 0 An off delay may not be set Connecti...

Page 41: ...rlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 without restart interlock with start up testing two hand standard Acts only on Q3 Q4 Switch off path B Two hand control unit to EN 574 IIIA with jog mode Jog mode max 5 s Q3 Q4 remain switched on for only 5 s Two hand control unit to EN 574 IIIA without jog mode OR limited 60 s w...

Page 42: ... without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 with restart interlock Q3 Q4 without EDM Q3 without restart interlock Q3 Q4 without EDM Q3 with restart interlock Q3 Q4 with EDM Q3 without restart interlock Q3 Q4 with EDM Q3 OR limited 60 s with UE410 8DI switch position 8 Always wire ENABLE expected 24 V D...

Page 43: ...of S1 with restart interlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 with restart interlock Q3 Q4 without EDM Q3 without restart interlock Q3 Q4 without EDM Q3 with restart interlock Q3 Q4 with EDM Q3 without restart interlock Q3 Q4 with EDM Q3 OR limited 60 s with UE410 8DI switch...

Page 44: ... S1 with restart interlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 with restart interlock Q3 Q4 without EDM Q3 without restart interlock Q3 Q4 without EDM Q3 with restart interlock Q3 Q4 with EDM Q3 without restart interlock Q3 Q4 with EDM Q3 OR limited 60 s with UE410 8DI switch p...

Page 45: ...rlock Q1 Q2 without EDM without restart interlock Q1 Q2 without EDM with restart interlock Q1 Q2 with EDM without restart interlock Q1 Q2 with EDM Connecting of S2 with restart interlock Q3 Q4 without EDM Q3 without restart interlock Q3 Q4 without EDM Q3 with restart interlock Q3 Q4 with EDM Q3 without restart interlock Q3 Q4 with EDM Q3 OR limited 60 s with UE410 8DI switch position 8 Always wire...

Page 46: ...s of logic path A Inputs of logic path B 0 Module inactive Dual channel non isolated semiconductors UB I3 UB I4 Dual channel equivalent N C contact cross circuit detecting synchronisation time monitoring 1500 ms X1 I1 X2 I2 Dual channel N C contact three wire UB I3 UB I4 1 Four wire cross circuit detecting e g cross circuit detecting switching mats X1 I1 X2 I2 Single channel N C contact UB I3 UB I...

Page 47: ...annel N C contacts IN4000 inductive switch with semiconductor output X1 I1 bridge X2 I2 4 Two hand control X1 I1 N O contact X1 I2 N C contact X1 I1 X1 I2 Two hand control X1 I3 N O contact X2 I4 N C contact X2 I3 X2 I4 5 Dual channel equivalent N C contact cross circuit detecting X1 I1 X2 I2 2 single channel N O contacts cross circuit detecting X1 I3 X2 I4 6 Dual channel equivalent N C contact cr...

Page 48: ... Dual channel non isolated semiconductors UB I3 UB I4 Dual channel N C contact three wire UB I1 UB I2 Dual channel N C contact three wire UB I3 UB I4 8 Single channel N C contact UB I1 UB I2 Single channel N C contact UB I3 UB I4 Dual channel non isolated semiconductors UB I3 UB I4 Dual channel N C contact three wire UB I3 UB I4 9 Dual channel equivalent N C contact cross circuit detecting X1 I1 X...

Page 49: ...unction I3 I4 local emergency stop Moni toring Function I6 reset of the local emergency stop 5 1 2 Manual 3 Equivalent switch cross circuit detecting I3 X1 I4 X2 Automatic 4 Manual 5 Dual channel N C N O contact complementary cross circuit detecting I3 X1 I4 X2 Automatic 6 Manual 7 OSSD or untested safety switch I3 Ux 6 I4 Ux Automatic 8 Manual 9 Equivalent switch cross circuit detecting Single ch...

Page 50: ...N C contact not cross circuit detecting ESPE and sensors with semiconductor output OR with UE410 8DI switch position 7 input B Switch position 7 input A is not permitted UE410 GU switches to ERROR configuration error AND with UE410 8DI switch position 1 6 Global reset connecting of I6 with restart interlock Q1 Local reset connecting of I6 with restart interlock Q1 only in the programs 2 4 6 8 OR l...

Page 51: ...AND linked and form an input pair This does not apply for switch position 1 Switch position Description 0 Selected input A B is inactive input signals are ignored 1 The connected single channel sensor equipment is AND linked to the respective logic path of the UE410 MU UE410 GU UE410 XU modules Unused inputs have to be jumpered in accordance with the state logical 1 e g X4 I4 UB I4 2 6 The connect...

Page 52: ...tton Safety switch Testable sensors Single channel N C contact 2 Emergency stop button Safety switch Switching mat pressure sensitive Flexi Loop Dual channel N C contact equivalent cross circuit detecting 3 Emergency stop button Safety switch Flexi Loop Dual channel N C contact equivalent cross circuit detecting synchronous time monitoring 1500 ms 4 Safety switch Dual channel N C N O contact compl...

Page 53: ...C contact equivalent 7 Safety switch ESPE e g C4000 Dual channel semiconductor output 3 8 3 Bypass The switch position 8 of the UE410 8DI jumpers the outputs of the UE410 MU UE410 XU modules for the maximum duration of 60 s The bypass is only active if I1 and I2 or I5 and I6 are logical 1 input pairs I3 I4 and I7 I8 do not have to be wired they have no function Bypass function on the UE410 GU via ...

Page 54: ...dd i e X1 and X3 or two evenly i e X2 and X4 numbered outputs will not be detected Please heed this when wiring the safety sensors The assignment of outputs X1 to X8 to inputs I1 to I8 depends on the selected rotary switch position The functions of logic paths A and B can be set independently of each other When AND logic is used unused inputs have to be jumpered in accordance with the state logica...

Page 55: ...or I2 OSSD1Sensor I3 OSSD2Sensor I4 OSSD1Sensor I5 OSSD2Sensor I6 OSSD1Sensor I7 OSSD2Sensor I8 AND 2 dual channel three wire UB I1 UB I2 UB I3 UB I4 UB I5 UB I6 UB I7 UB I8 6 AND 2 single channel UB I1 UB I2 UB I3 UB I4 UB I5 UB I6 UB I7 UB I8 OR 2 dual channel semiconductor OSSD1Sensor I1 OSSD2Sensor I2 OSSD1Sensor I3 OSSD2Sensor I4 OSSD1Sensor I5 OSSD2Sensor I6 OSSD1Sensor I7 OSSD2Sensor I8 OR ...

Page 56: ... I4 flash out of phase Process error at I3 I4 I5 I6 flash out of phase Process error at I5 I6 I7 I8 flash out of phase Process error at I7 I8 I1 or I2 flashing Synchronous time 1500 ms exceeded I3 or I4 flashing Synchronous time 1500 ms exceeded I5 or I6 flashing Synchronous time 1500 ms exceeded I7 or I8 flashing Synchronous time 1500 ms exceeded QA green Input conditions input A of inputs I1 to ...

Page 57: ...page 78 3 9 UE410 2RO UE410 4RO output modules The UE410 2RO UE410 4RO output modules make dual channel contact based outputs with positively guided relay contacts available The output modules may only be operated in a system combination with a UE410 MU XU A maximum of four UE410 4RO or eight UE410 2RO can be connected to a Flexi Classic system The slot of an output module in the Flexi Classic sys...

Page 58: ...wn path comprising two safe enable current paths 13 14 23 24 dual channel and floating one safe enable current path Y14 dual channel and not floating one external device monitoring feedback circuit Y1 Y2 dual channel and floating Control input B2 operates two internal relays and forms one redundant shutdown path comprising two safe enable current paths 33 34 43 44 dual channel and floating one saf...

Page 59: ...toring EDM N C contact Y14 N O safety contact K1 K2 current limited see chapter 11 Technical specifications on page 96 3 9 5 UE410 4RO inputs and outputs Assignment Description B1 Connecting relay K1 K2 B2 Connecting relay K3 K4 13 14 and 23 24 Safety contacts for switch off circuit outputs K1 K2 33 34 and 43 44 Safety contacts for switch off circuit outputs K3 K4 Y1 Y2 Feedback EDM K1 K2 N C cont...

Page 60: ...nd functions that can be implemented with a Flexi Classic system These are the connection and configuration of the safety sensors and the settings at the Flexi Classic system RE300 magnetic safety switch IN4000 inductive safety switch connection of testable single beam photoelectric safety switches two hand operation jog mode OR function muting function bypass function connecting of S1 S2 S3 resta...

Page 61: ...nd I4 on the UE410 GU in program 4 or 5 The necessary test signals X1 X2 for the magnetic safety switch RE300 meet the requirements for applications up to PL e as per EN ISO 13849 1 Pay attention to the safety notes for the RE300 switch If RE300 sensors are cascaded these have to be tested activated regularly for example opening and closing of the protective doors connected to the sensors Cascadin...

Page 62: ...generated in the program 3 2 of the UE410 MU UE410 XU Up to nine safety sensors can be cascaded per input Inductive safety switches IN4000 cannot be connected to a UE410 GU Connection A safety sensor cascade is connected to the input I1 and test output X1 Further information is available in the IN4000 operating instructions Input I2 and test output X2 have to be jumpered Terminal S2 may not be int...

Page 63: ...UE410 8DI the required test signals are generated at outputs X1 to X8 Up to 4 testable single beam photoelectric switches can be cascaded per input This means at the modules UE410 MU UE410 GU UE410 XU with one input I2 each respectively at the UE410 8DI with inputs I1 to I8 A selection of the testable single beam photoelectric safety switches is available in section 12 2 Accessories spare parts on...

Page 64: ...tches If several pairs of single beam photoelectric safety switches are used it is imperative that the aperture angle of the sensors is observed to avoid the possibility of mutual interference If the senders are only mounted on one side the light beams may not overlap on the receiver side i e the light beam of one sender may not reach two receivers If the senders and receivers are mounted alternat...

Page 65: ...le beam photoelectric safety switches with a field of view of 10 is calculated as follows If the distance D 3 m the minimum distance a 260 mm If the distance D 3 m the minimum distance a is calculated using the following equation a mm 88 2 D 10 m Example Distance D between the sender and receiver amounts to 28 m With the corresponding value entered a mm 88 2 28 m 10 2469 6 mm The minimum distance ...

Page 66: ...ing up procedures The two hand operation function in accordance with type IIIA can be set in program 5 1 of the UE410 MU UE410 XU Two equivalent inputs N O contacts of both two hand buttons are monitored A valid input signal is only generated if the ON state H level exists at both inputs within a period of 0 5 s synchronous change both two hand buttons pressed and if both were in the OFF state L l...

Page 67: ...using an OR signal Thus for example a safety function can be muted in set up mode by means of an enabling switch An OR link of two safety functions is also possible The OR function does not have a time limit OR function with input extension module All the programs of the main module offer the possibility of linking signals of the OR func tion at the UE410 8DI input extension modules to the input s...

Page 68: ...he UE410 GU Pay attention to the following safety notes Muting is only allowed to be activated during the period when the material to be trans ported e g on a pallet blocks the access to the hazardous area Muting must be triggered by at least two independently wired signals e g from muting sensors and must not depend entirely on software signals for instance from a PLC Muting must be removed immed...

Page 69: ...cycle ends when the last muting sensor returns to its initial state e g clear light path for optical sensors Only then is it possible to activate muting again Material can be transported several times during a muting cycle if the muting condition is maintained continuously i e at least one pair of sensors remains activated continuously 4 6 3 Muting sensors Muting sensors detect material and supply...

Page 70: ...al 0 a minimum distance to the light beams on the ESPE 1 is maintained The minimum distance provides the processing time necessary until muting is activated How to calculate the minimum distance S v 61 ms Where S minimum distance mm v velocity of the material e g of the conveyor m s Use optical sensors with background suppression These detect material only up to a specific distance Objects that ar...

Page 71: ... calculate the distance S1 v 61 ms Where S1 minimum distance between the light beams of the ESPE and the detection by the muting sensors mm v velocity of the material e g of the conveyor m s The material can flow in both directions In order for materials to be conveyed in both directions place the intersection of the muting sensors 0 exactly on the course of the light beams of the ESPE In order fo...

Page 72: ... the muting function for UE410 MU UE410 XU The outputs on the muting sensors must be 0 on powering up the Flexi Classic other wise a process error will be generated and the system will generate ERROR Muting duration indefinite Switching behaviour of the muting sensors is not limited in time Direction independent muting Inputs I3 I4 for muting sensors can be 1 simultaneously The muting lamp is not ...

Page 73: ...WT24 2 WT27 3 Photoelectric proximity switch WT260 Light switching WL23 2 WL27 3 WL260 WL12 3 WL14 2 Photoelectric reflex switch WL18 3 Dark switching WS WE24 2 WS WE27 3 Through beam photoelectric switch WS260 WE260 Dark switching For the selection and settings for the SICK optical muting sensors in muting applications the following applies The outputs must be PNP switching Other type series are ...

Page 74: ... the safety outputs of the UE410 MU UE410 GU UE410 XU modules are activated You have to ensure that there is no danger to persons or parts of the machine or system during bypass operation The bypass function may only be activated by a key operated switch with an automatic reset and two levels or by two input signals that are independent of each other e g two position switches Check the connected k...

Page 75: ...ncelling the restart interlock is only fulfilled when the reset button is pressed and released again and the feedback circuit is closed 4 10 2 Operation without restart interlock The outputs are activated as soon as the input conditions of the safety sensors have the value of logical 1 A reset button is not required 4 10 3 Operation with external device monitoring EDM The static EDM monitors wheth...

Page 76: ... pushbutton is reset again before the delay time has expired and the reset button is pressed the releases are never theless de activated Renewed releasing via the reset button is not possible until the delay time has expired Retriggering Course ON If the safe input state all input conditions are valid of the input circuits is attained again before the time has expired the delayed output circuits d...

Page 77: ...the connection of S1 S2 and S3 cause a lock out ERR During the configuration phase when the voltage is activated of the manual reset with the reset button the corresponding S input must be open or be connected to a high resistance output for example of a PLC high or low potential causes an incorrect configuration In order to monitor external contactors that may be connected to the safe outputs Q1 ...

Page 78: ...dance with EN ISO 13849 1 or SILCL3 in accord ance with EN 62061 Exclude cross circuits by means of appropriate cabling If several modules are used 1 cross circuits on test pulse outputs X1 Xn can not always be detected If two modules are used UE410 MU or UE410 GU and a UE410 XU cross circuits on safety outputs Q1 Q4 can not always be detected If several modules are used the possibility of cross c...

Page 79: ...s it possible to cascade safety circuits or to form sub systems The ENABLE input has a higher priority than all other input signals sensors muting bypass OR function Unused ENABLE inputs must be connected to the supply voltage UB When the ENABLE input goes low 0 V DC the OSSDs Q1 Q4 always go low and at the same time no signal such as a reset or muting is detected until ENABLE is high again Switch...

Page 80: ...control cabinet rated to at least IP 54 In a Flexi Classic system the main module UE410 MU is positioned at the extreme left and one of the optional gateways e g UE410 PRO at the extreme right The connection between the modules is effected by means of the plug connection integrated in the housing Mounting according to EN 50274 The modules are located in a 22 5 mm wide housing for 35 mm DIN mountin...

Page 81: ...g If there are several modules slide the modules together individually in the direction of the arrow until the side plug connection latches in Install end clips on the right and left 5 2 Steps for dismantling the modules Remove the plug in terminals with wiring and the end clips Fig 36 Installing the end clips Fig 37 Removing the plug in terminals Fig 38 Disconnecting the plug connection ...

Page 82: ... the module downwards 0 and remove it from the DIN mounting rail in the direction of the arrow while keeping it pressed down 1 5 3 Removing the anti manipulation cover To prevent tampering on the Flexi Classic SICK provides an optional anti manipulation cover see section 12 2 6 Anti manipulation cover on page 117 Insert a screwdriver in the opening 0 The cover fastening is released by upward movem...

Page 83: ...g 20 ms Suitable power supplies are available as acces sories from SICK When several power supplies are used all mass connections GND must be connected to each other All UE410 GU modules that are on a common global emergency stop cut off path must be connected to the same GND connection The power supply as well as all signals connected have to fulfil the regulations for extra low voltages with saf...

Page 84: ...arating effected wires single plastic sheathed cable etc For more informationen on this topic see section 4 12 Grouping of subsystems on page 78 Special features to note during wiring A UE410 8DI has two test pulse generators This means that short circuits between odd X1 and evenly X2 numbered outputs will be detected Short circuits between two odd i e X1 X3 X5 X7 or two evenly i e X2 X4 X6 X8 num...

Page 85: ...grams By taking into account all the necessary boundary conditions and their evaluation in a Failure Mode and Effects Analysis FMEA applications up to a maximum of SIL3 IEC 61508 can be achieved 7 1 L21 on the UE410 MU XU Program 3 2 with restart interlock and EDM 7 2 Emergency stop on the UE410 MU XU Program 1 with restart interlock and EDM Note Fig 41 Connection of three L21 to the UE410 MU XU F...

Page 86: ...ect to change without notice Application examples and connection diagrams 7 3 RE300 on the UE410 MU XU Program 2 with restart interlock and EDM 7 4 Two hand IIIC on the UE410 MU XU Program 4 without restart interlock and with EDM Fig 43 Connection of an RE300 to the UE410 MU XU Fig 44 Connection of a two hand switch IIIC to the UE410 MU XU ...

Page 87: ...on examples and connection diagrams 7 5 C2000 and emergency stop on the UE410 MU XU two hazardous areas Program 7 with restart interlock and EDM 7 6 i11 on the UE410 MU XU two independent hazardous areas Program 8 with restart interlock and EDM Fig 45 Connection of a C2000 and emergency stop to the UE410 MU XU Fig 46 Connection of two i11 to the UE410 MU XU two hazardous areas ...

Page 88: ...hout notice Application examples and connection diagrams 7 7 IN4000 on the UE410 MU XU Program 3 2 with restart interlock and EDM 7 8 C4000 on the UE410 MU XU 2 sensor muting Program 3 1 with restart interlock and EDM Fig 47 Connection of two IN4000 to the UE410 MU XU Fig 48 Connection of a C4000 to the UE410 MU XU 2 sensor muting C4000 FE must be connected ...

Page 89: ... SICK AG Industrial Safety Systems Germany All rights reserved 89 Subject to change without notice Application examples and connection diagrams 7 9 Global emergency stop with two UE410 GU Program 1 global emergency stop only Fig 49 Global emergency stop with two UE410 GU ...

Page 90: ...The general acceptance comprises the following test points Check whether the connection of the components to the connections corresponds to the required Performance Level in accordance with EN ISO 13849 1 or to the SIL in accordance with IEC 61508 or the SILCL in accordance with EN 62061 Check the devices connected to the safety controller in accordance with the test notes from the accompanying op...

Page 91: ... Flexi Classic system must be tested regularly In order to reach SILCL3 in accordance with EN 62061 see chapter 11 Technical specifications on page 96 the following test must be made at least every 365 days The Flexi Classic system must be powered down The Flexi Classic system must be powered up All safety functions of the connected safety sensors must be verified 8 2 3 Regular inspection of the p...

Page 92: ... programs and functions at the rotary switches of all the modules of the system Set the control functions at all the modules of the system by external connecting of the terminals S1 S2 and S3 Switch on the voltage supply of all the modules while keeping the ENTER button of the main module UE410 MU or UE410 GU pressed Do not actuate any of the RESET buttons connected when in this state When the ERR...

Page 93: ... MU and UE410 GU Each time a device is replaced it is necessary to accept the system configuration again see section 9 1 Accepting the system configuration on page 92 UE410 XU If in an existing Flexi Classic system a device is replaced by another device with a differing revision code e g C XX to E XX then it is necessary to accept the system configuration again see section 9 1 Accepting the system...

Page 94: ... that did not detect the error initially Eliminate the error at the respective module 2 Error at the module configuration Repeat the configuration 3 Rotary switch manipulated Turn the rotary switch back to the original position Carry out a power up or repeat teaching in 4 Change to the configuration in the electrically unpowered state on the rotary switch or to S1 S3 UE410 MU XU only or Slot list ...

Page 95: ... inputs S1 S2 S3 Reset the old configuration at S1 S2 S3 Restart the system by switching the voltage off and on again The last configurations are saved internally in non volatile memory and can be read by the manufacturer if required Intentional use of an incorrect configuration You can read out the last correct configuration using one of the Flexi Classic Gateways Check the configuration visually...

Page 96: ...tion 4 A gG with tripping characteristic B or C Input circuit I1 I4 EN S1 S3 Number of inputs 8 Input voltage high 13 V DC 30 V DC Input voltage low 5 V DC 5 V DC Input current high 2 4 mA 3 mA 3 8 mA Input current low 2 5 mA 2 1 mA Input capacitance 9 nF 10 nF 11 nF Minimum switch off time 10 I1 I2 program 3 1 7 8 7 ms Minimum switch off time 10 I1 I2 program 1 2 4 5 6 9 20 ms Minimum switch off ...

Page 97: ...6 V DC 30 V DC Output current 15 120 mA Test period X1 X2 program 1 2 4 5 6 9 40 ms Test period X1 X2 program 3 2 X1 384 ms X2 40 ms Load capacity 1 000 nF Cable resistance 100 Ω Output circuit Q1 Q2 Q3 Q4 Number of outputs 4 Type of output PNP semiconductors short circuit protected cross circuit detecting 14 Switching voltage 18 4 V DC 30 V DC Switching current IQn TA 45 C 2 0 A IQn TA 55 C 1 6 A...

Page 98: ... 1 5 mm 2 100 m Response time I1 I2 16 program 3 1 7 8 13 ms Response time I1 I2 16 program 1 2 4 5 6 9 29 ms Response time I1 I2 16 program 1 pressure sensitive mat 38 ms Response time of all programs with tested ESPE Cat 4 e g L41 56 ms Response time I3 I4 16 program 1 2 7 8 9 13 ms Response time I3 I4 16 program 4 5 29 ms Response time I1 X1 I2 X2 16 program 3 2 79 ms 29 ms Response time 17 on ...

Page 99: ...re UL CSA ambient temperature 25 C 55 C Storage temperature 25 C 70 C Air humidity 10 to 95 non condensing Climatic conditions EN 61131 2 Mechanical strength Vibration EN 61131 2 Vibration resistance 5 500 Hz 5 grms EN 60068 2 64 Terminal and connection data Single wire or fine wire 1 0 14 mm to 2 5 mm or 2 0 14 mm to 0 75 mm Fine wire with terminal crimps to EN 46228 1 0 25 mm to 2 5 mm or 2 0 25...

Page 100: ...4 EN ISO 13849 1 Performance Level19 PL e EN ISO 13849 1 TM mission time 20 years EN ISO 13849 1 PFD 3 9 10 6 PFHd 1 h 2 5 10 9 SFF 96 DC 99 Single channel input single channel output Single channel input dual channel output Dual channel input single channel output Dual channel input dual channel output PFD 2 2 10 5 5 2 10 6 2 1 10 5 3 9 10 6 of SIL3 2 2 0 5 2 1 0 4 PFHd 1 h 6 0 10 9 2 5 10 9 6 0 ...

Page 101: ...cuit protection 4 A gG with tripping characteristic B or C Input circuit I1 I4 IP I5 I6 IN Number of inputs 8 Input voltage high 13 V DC 30 V DC Input voltage low 5 V DC 5 V DC Input current high 2 4 mA 3 mA 3 8 mA Input current low 2 5 mA 2 1 mA Input capacitance 9 nF 10 nF 11 nF Minimum switch off time 20 I1 I2 20 ms Minimum switch off time 20 I3 I4 program 6 7 7 ms Minimum switch off time 20 I3...

Page 102: ...ed cross circuit monitored21 Switching voltage 18 4 V DC 30 V DC Switching current IQn TU 45 C 2 0 A IQn TU 55 C 1 6 A Total current Isum Σ IQn TU 45 C 4 A Σ IQn TU 55 C 3 2 A Load diagram for the Q1 and Q2 outputs of the UE410 GU modules Test pulse width 500 μs 640 μs 700 μs Test pulse frequency 12 5 Hz 32 Hz Inductive switch off energy E 0 5 L I 370 mJ 21 Cross circuit detecting only within a mo...

Page 103: ...100 m Cable length all stations global emergency stop function 25 1000 m Number of stations global emergency stop function 32 Global response time IX to OX 40 ms Global power up delay IX 80 ms 120 ms General system data Weight without packaging 0 18 kg Electrical safety Class III Interference resistance EN 61000 6 2 Radiated emission EN 61000 6 4 Operating data Ambient operating temperature UL CSA...

Page 104: ... flexible wire Tightening torque 5 7 lb in UE410 xx4 UE410 xxx4 Connection cross section AWG 30 12 only use 60 75 C copper flexible wire Safety specific characteristics All these data are based on an ambient temperature of 40 C Safety Integrity Level 26 SIL3 IEC 61508 SIL claim limit 26 SILCL3 EN 62061 Category Category 4 EN ISO 13849 1 Performance Level 26 PL e EN ISO 13849 1 TM mission time 20 y...

Page 105: ...put PNP semiconductors short circuit protected cross circuit detecting 27 Output voltage 16 V DC 30 V DC Output current 28 30 mA Test period 40 ms Load capacity 1 000 nF Cable resistance 100 Ω Response time UE410 8DI on safety outputs UE410 MU UE410 XU Q1 Q4 Response time switch setting 6 7 29 17 ms Response time switch setting 1 2 3 4 5 829 34 ms Response time switch setting 2 pressure sensitive ...

Page 106: ...1 2 Mechanical strength Vibration EN 61131 2 Vibration resistance 5 500 Hz 5 grms EN 60068 2 64 Terminal and connection data Single wire or fine wire 1 0 14 mm to 2 5 mm or 2 0 14 mm to 0 75 mm Fine wire with terminal crimps to EN 46228 1 0 25 mm to 2 5 mm or 2 0 25 mm to 0 5 mm Insulation stripping length 8 mm Maximum tightening torque 0 6 Nm For UL 508 and CSA applications UE410 xx3 UE410 xxx3 C...

Page 107: ...utput Single channel input dual channel output Dual channel input single channel output Dual channel input dual channel output PFD 2 4 10 5 7 0 10 6 2 3 10 5 5 8 10 6 of SIL3 2 4 0 7 2 3 0 6 PFHd 1 h 7 3 10 9 3 8 10 9 7 3 10 9 3 8 10 9 of SIL3 7 3 3 8 7 3 3 8 11 1 4 UE410 2RO UE410 4RO output modules Minimum Typical Maximum Supply circuit via UE410 MU Power consumption UE410 4RO 3 2 W UE410 2RO 1 ...

Page 108: ...230 V DC 253 V DC Switching voltage DC Maximum DC current UE410 2RO UE410 4RO Switching current 10 mA 6 A Minimum contact load with Un 24 V DC 50 mW Total current 8 A Response time32 30 ms Type of output Floating N O contacts positively guided Contact material AgSnO2 Output circuit fusing 6 A gG per current path AC 15 Ue 250 V Ie 3 A Usage category DC 13 Ue 24 V Ie 3 A 32 Time from LOW on B1 B2 to...

Page 109: ...a Electrical isolation Supply circuit input circuit No Supply circuit output circuit Yes Input circuit output circuit Yes Weight without packaging UE410 2RO 0 16 kg UE410 4RO 0 19 kg Operating data Ambient operating temperature UL CSA ambient temperature 25 C 55 C Storage temperature 25 C 70 C Air humidity 10 to 95 non condensing Climatic conditions EN 61131 2 Mechanical strength Vibration resista...

Page 110: ... 8 mm Maximum tightening torque 0 6 Nm For UL 508 and CSA applications UE410 xx3 UE410 xxx3 Connection cross section AWG 30 12 only use 60 75 C copper flexible wire Tightening torque 5 7 lb in UE410 xx4 UE410 xxx4 Connection cross section AWG 30 12 only use 60 75 C copper flexible wire Safety specific characteristics All these data are based on an ambient temperature of 40 C Safety integrity level...

Page 111: ... AC15 5 1 h 8760 70 000 7 20 x 10 08 1 1 h 8760 2 000 000 2 50 x 10 09 DC13 3 1 h 8760 450 000 1 10 x 10 08 2 1 h 8760 1 000 000 5 00 x 10 09 AC1 4 1 h 8760 600 000 8 40 x 10 09 11 2 Dimensional drawings 11 2 1 UE410 MU and UE410 GU main modules 11 2 2 UE410 XU UE410 8DI UE410 2RO UE410 4RO UE410 PRO UE410 DEV UE410 CAN modules Tab 46 PFHd values Fig 50 Dimensional drawing UE410 MU and E410 GU mm ...

Page 112: ...26137 UE410 MU3T300 Main module 4 inputs 4 outputs Delay possible 0 300 s Plug in screw terminals 6026138 UE410 GU Main module 4 inputs 1 output Plug in screw terminals 1072177 UE410 8DI3 Input extension module 4 dual channel inputs Plug in screw terminals 6026139 UE410 2RO3 Output module 2 N O contacts and 1 24 V DC alarm signal Plug in screw terminals 6026144 UE410 4RO3 Output module 4 N O conta...

Page 113: ...0 MU4T5 Main module 4 inputs 4 outputs Delay possible 0 5 s Plug in spring terminals 6032669 UE410 MU4T50 Main module 4 inputs 4 outputs Delay possible 0 50 s Plug in spring terminals 6032670 UE410 MU4T300 Main module 4 inputs 4 outputs Delay possible 0 300 s Plug in spring terminals 6032671 UE410 XU4T0 Input output extension module 4 inputs 4 outputs No delay Plug in spring terminals 6035245 UE41...

Page 114: ...ontacts and 1 24 V DC alarm signal Plug in spring terminals 6032677 UE410 PRO3 PROFIBUS DP gateway Plug in screw terminals 6028407 UE410 PRO4 PROFIBUS DP gateway Plug in spring terminals 6032678 UE410 CAN3 CANopen gateway Plug in screw terminals 6033111 UE410 CAN4 CANopen gateway Plug in spring terminals 6033112 UE410 DEV3 DeviceNet gateway Plug in screw terminals 6032469 UE410 DEV4 DeviceNet gate...

Page 115: ...hotoelectric safety switch sender 24 V DC operating range 5 m radial axis PNP physical size M18 M12 4 plug 6034876 L21E 11MA1A Single beam photoelectric safety switch receiver 24 V DC operating range 5 m radial axis PNP physical size M18 M12 4 plug 6034877 L27S 3D2430 Single beam photoelectric safety switch sender 24 V DC operating range 25 m PNP Q Q M12 4 plug 2043906 L27E 3P2430 Single beam phot...

Page 116: ...ating range 5 m radial axis PNP physical size M18 M12 4 plug 6034869 12 2 2 Non contact safety switches Part Description Part number RE21 DA05 RE21 sensor and actuator 5 m cable 6035617 RE27 DA05L RE27 sensor and actuator 5 m cable 6034343 RE13 DAC RE13 sensor and actuator M8 plug 6036769 RE31 DAC RE31 sensor and actuator M8 plug 6036768 T4000 E0101K T4000 Direct sensor 6035041 T4000 1KBQ Actuator...

Page 117: ...4 Safety laser scanners and safety camera system Part Description Part number S3000 All variants S300 All variants V300 All variants 12 2 5 Muting lamps and cables Part Description Part number Muting lamp with mounting kit 2020743 LED muting lamp with cable 2 m 2019909 LED muting lamp with cable 10 m 2019910 12 2 6 Anti manipulation cover Part Description Part number AM cover 10 anti manipulation ...

Page 118: ...nd on the application the requirements of which must be verified by the manufacturer installer This checklist should be retained and kept with the machine documentation to serve as reference during recurring tests 1 Have the safety rules and regulations been observed in compliance with the directives standards applicable to the machine Yes No 2 Are the applied directives and standards listed in th...

Page 119: ...Ds I5 and I6 on the UE410 GU 34 Tab 17 UE410 MU UE410 XU programs 36 Tab 18 Connection of sensors to the UE410 MU UE410 XU 48 Tab 19 UE410 GU programs 49 Tab 20 UE410 8DI switch positions 51 Tab 21 UE410 8DI switch positions 52 Tab 22 OR link UE410 8DI 53 Tab 23 Bypass UE410 8DI 53 Tab 24 Connection of sensors to the UE410 8DI 55 Tab 25 UE410 8DI LED indications 56 Tab 26 UE410 8DI operating eleme...

Page 120: ...cheme programs 5 7 9 23 Fig 6 Scheme program 8 23 Fig 7 UE410 MU controls and status indicators 24 Fig 8 UE410 GU controls and status indicators 28 Fig 9 Connecting several UE410 GU modules 30 Fig 10 Diagnostic displays on the UE410 GU 34 Fig 11 UE410 XU controls and status indicators 35 Fig 12 UE410 8DI controls and status indicators 56 Fig 13 Internal structure UE410 2RO 57 Fig 14 Internal struc...

Page 121: ...Disconnecting the plug connection 81 Fig 39 Removing the module from the DIN mounting rail 82 Fig 40 Anti manipulation cover 82 Fig 41 Connection of three L21 to the UE410 MU XU 85 Fig 42 Connection of an emergency stop to the UE410 MU XU 85 Fig 43 Connection of an RE300 to the UE410 MU XU 86 Fig 44 Connection of a two hand switch IIIC to the UE410 MU XU 86 Fig 45 Connection of a C2000 and emergen...

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